Method of producing a thin film solar cell having a n-i-p structure

ABSTRACT

A thin film solar cell with an n-i-p structure has roughened substrate surface and to achieve an improved fill factor, the substrate surface of the solar cell is a multiply concave surface and has no sharp points.

This is a divisional application of parent application Ser. No. 811,639, filed Dec. 20, 1985 now abandoned.

FIELD AND BACKGROUND OF THE INVENTION

This invention relates in general to solar cells and in particular to a new and useful thin film solar cell having a n-i-p structure which comprises a substrate having a roughened substrate surface with an n-layer for light entering the cell and wherein the surface consists mostly of concave surface portions with no sharp points.

Solar cells are to convert the greatest possible part of the irradiated light energy into electrical energy. In solar cells such as thin film solar cells of a-Si the light of the long wave spectral range is not absorbed completely. A part of the light not absorbed is reflected by a metallic backside contact and can be utilized again in the solar cell. To obtain the longest possible optical path for this reflected light in the active solar cell layer it is known to reflect the light not perpendicularly, but at a flat angle; this is achievable by using a suitably structured backside electrode ("light trapping"). The short-circuit current of the solar cell is increased in this manner (Journal I. Vac. Sci.Technol., Al(2), 1983, pages 578, 582).

The charge carrier drift plays a big role in a-Si solar cells (n-i-p cells). Therefore, the electric field curve in the solar cell is important. The electric field should be as uniform as possible inside the solar cell and should nowhere assume the value zero, otherwise the recombination of the charge carriers would be increased or the capture length reduced, and the fill factor would drop (Appl. Phys. Lett. 44 (5), 1984, pages 437-539).

SUMMARY OF THE INVENTION

The invention provides a method of forming thin film solar cell in which the recombination of the charge carriers is reduced and the fill factor is thus increased.

Accordingly it is an object of the invention to provide a method for forming a thin film solar cell with a n-i-p structure which comprises a substrate with a roughened substrate surface with an n-layer for light entering the cell and wherein the surface formed consists mostly of concave surface portions with no sharp points.

Accordingly an object of the invention is to provide a method for forming an improved solar cell construction with a surface having concave portions extending thereacross.

A further object of the invention is to provide a method of producing a solar cell wherein a substrate is first lapped with aluminum trioxide (Al₂ O₃) powder and water and the grain size of the powder is approximately 3 microns and thereafter the substrate material is abraded to a roughness of approximately 0.05 to 3 microns and thereafter etched with a hydrofluoric acid.

A further object of the invention is to provide a solar cell which is simple in design, rugged in construction and economical to manufacture.

The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a transverse sectional view of a thin film solar cell having a substrate surface of multiply concave design in accordance with the invention;

FIG. 2 is a diagram of the electric field strength in a plate capacitor and a spherical capacitor with the radii r₁ and r₂ with r₁ less than r₂, as may be seen from FIG. 1; the field of a plate capacitor being characterized by the unbroken curve G1 and that of a spherical capacitor by the broken curve K1;

FIG. 3 is a potential curve diagram in a solar cell structure with smooth and with mostly concave roughened substrate;

FIG. 4 is an energy band curve diagram in a solar cell with smooth and with multiply concave roughened substrate; and

FIG. 5 is a characteristic curve diagram of a-Si solar cells under AM1 lighting with smooth and with multiply concave roughened substrate.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings in particular, the invention embodied therein comprises a thin film solar cell with an n-i-p structure and which includes a substrate 1 having a roughened substrate surface with an n-layer for light entering the cell. The surface 1 is a mostly concave surface with no sharp points.

In FIG. 1 may be seen a cutout of a roughened, mostly concave structure of an a-Si solar cell comprising a substrate 1, a metal film 2, an n-i-p-a-Si diode 3, an antireflection film 4 and an electric field F. The light penetrates the antireflection film 4 and another n-doped film of the n-i-p solar cell (not shown) and enters the active i-a-Si film of the solar cell at r₁. R marks the surface roughness. The structure can be imagined as being constructed of spherical surfaces with the radii r₁ and r₂. The areas at the rim of each concave surface are neglected because they contribute little to the total surface. The intensity of the electric field increases in the concave areas near r₁ and decrease near r₂, as indicated by the curve K1 in FIG. 2. A statistically roughened substrate corresponds here in the mean to a smooth substrate, indicated by the curve G1. For a substrate surface designed multi-ply concave this leads to a substantially straight potential response curve and to a more favorable potential curve K2 in the solar cell, as may be seen from FIG. 3.

FIG. 4 shows the improved energy band curve K3 of a solar cell diode 3 with mostly concave substrate surface portions versus the energy band curve G3 of a solar cell with smooth substrate surface. As the shape of curve K3 demonstrates, the recombination of the charge carriers is reduced by the stronger electric field at the solar cell side (r₁) facing the light where the great majority of the light is absorbed. Also, the field in the i-a-Si layer of the solar cell is distributed more evenly between the doped areas at r₁, r₂ of the diode 3. This also reduces the recombination of the charge carriers. The reduction of the charge carrier recombination leads to a higher fill factor of the solar cell characteristic and besides the improvement of the short circuit current in roughened substrates, to a greater efficiency of the solar cell.

FIG. 5 shows the improvement of the solar cell characteristic of two a-Si solar cells under AM1 lighting of the type A1-ITO-n-aSi-i-aSi-p-aSi-Ti-glass, the characteristic G4 relating to a smooth and the characteristic K4 to a multiply concave roughened substrate surface. The fill factors FF_(G) and FF_(K) of the solar cells in this example are 0.39 for the cell with smooth, and 0.46 for the cell with concave roughened substrate surface. The improvement of the fill factor brought about by the mostly concave roughened substrate surface portions amounts to about 18%.

In the following, an example of the production of a solar cell with multi-ply concave roughened substrate surface is discussed.

The substrate material, quartz or glass, is lapped with Al₂ O₃ powder and water. The grain size of the Al₂ O₃ powder is about 3 μm. The material abrasion must be such that a surface roughness R of approximately 0.5 to 3 μm is obtained uniformly over the entire substrate. The substrate is subsequently cleaned in boiling trichlorethylene to dissolve the layer of wax used to fasten the substrate for lapping. Thereafter, the substrate is cleaned twice in boiling acetone. After additional cleaning steps the substrate is etched for about two seconds in hydrofluoric acid in an ultrasonic bath. It is then rinsed in warm water, for at least one minute; and for at least one minute in distilled water in the ultrasonic bath. Subsequently, the substrate is dried. The sharp points on the substrate are rounded off by the etching operation in hydrofluoric acid. This avoids short-circuits in the solar cell.

While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. 

What is claimed is:
 1. A method of producing a solar cell using a substrate material, comprising the steps of:lapping the substrate material with Al₂ O₃ powder having a grain size substantially equal to 3 microns; abrading the surface of the substrate to obtain a surface roughness of substantially 0.5 to 3 microns; and, subsequently etching the surface of the substrate with hydrofluric acid for a time period substantially equal to 2 seconds in an ultrasonic bath.
 2. A method according to claim 1, wherein the surface of the substrate has an n-layer for light entering the cell through said n-layer and wherein the surface of the solar cell is formed as a multi-ply concave surface having no sharp points.
 3. A method according to claim 1, including providing the entire surface with concave portions extending one after the other across said surface.
 4. A method according to claim 1, including providing an antireflection film on said substrate surface.
 5. A method according to claim 1, including applying a metal film on said surface and an antireflection film over said metal film.
 6. A method of producing a solar cell using a substrate material, comprising the steps of: lapping the substrate material with Al₂ O₃ powder having a grain size substantially equal to 3 microns; abrading the surface of the substrate to obtain a surface roughness of substantially 0.5 to 3 microns; and, providing a substrate surface comprising mostly concave portions with irregularities by subsequently etching the surface of the substrate with hydrofluric acid for a period substantially equal to 2 seconds in an ultrasonic bath. 